US 8,797,627 B2Granted

Exterior rearview mirror assembly

AssigneeDonnelly Corporation

InventorsIan A. McCabe, Desaraju V. Varaprasad, Hamid Habibi, Niall R. Lynam

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Abstract

An exterior rearview mirror assembly includes a variable reflectance mirror reflective element. A mirror reflector of the mirror reflective element includes a stack of thin films having at least two thin films. At least one of the thin films is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm, and at least one of the thin films is a thin metal film. An electrochromic medium is disposed in an interpane cavity of the mirror reflective element and is bounded by a perimeter seal. A reflective perimeter layer is disposed at a second surface of a front substrate proximate a perimeter edge of the front substrate. The perimeter layer generally conceals the perimeter seal from view by a driver of the vehicle normally viewing the front substrate when the exterior rearview mirror assembly is mounted at the vehicle.

Claims76

Dependent claims

An exterior rearview mirror assembly suitable for use for a vehicle, said exterior rearview mirror assembly comprising:

a casing portion;
wherein said casing portion comprises a variable reflectance mirror reflective element;
an attachment portion;
wherein said attachment portion is configured for attaching at a side of a vehicle;
wherein said mirror reflective element comprises a front substrate and a rear substrate and an electrochromic medium disposed between said front and rear substrates;
wherein said front substrate has a first surface and a second surface and wherein a transparent electrically conductive layer is disposed at said second surface of said front substrate;
wherein said rear substrate has a third surface and a fourth surface and wherein a mirror reflector is disposed at at least a portion of said third surface of said rear substrate;
wherein said mirror reflector comprises a stack of thin films and wherein said stack of thin films comprises at least two thin films;
wherein at least one of said thin films is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm;
wherein at least one of said thin films comprises a thin metal film;
wherein said electrochromic medium is disposed in an interpane cavity between said third surface of said rear substrate and said second surface of said front substrate and is bounded by a perimeter seal;
wherein no part of said rear substrate extends beyond any part of said front substrate;
wherein a perimeter layer is disposed at said second surface of said front substrate proximate a perimeter edge of said front substrate, and wherein said perimeter layer comprises a reflective perimeter layer;
wherein said perimeter layer comprises at least one thin metal film and wherein said perimeter layer is electrically conductive;
wherein said perimeter layer generally conceals said perimeter seal from view by a driver of the vehicle normally viewing said front substrate when said exterior rearview mirror assembly is mounted at the vehicle;
wherein said exterior rearview mirror assembly comprises a light source and wherein said light source is at least one of (i) disposed rearward of said mirror reflective element and, when actuated, illuminates through said mirror reflective element, (ii) disposed at said casing portion and (iii) disposed at said attachment portion;
wherein said light source comprises a plurality of light emitting diodes, and wherein at least some of said light emitting diodes each individually passes less than about 75 milliamps forward current when powered;
and
wherein light emitted by said light source when powered is substantially not visible to the driver of the vehicle when the driver is normally operating the vehicle.

16 more elements

An exterior rearview mirror assembly suitable for use for a vehicle, said exterior rearview mirror assembly comprising:

a casing portion;
wherein said casing portion comprises a variable reflectance mirror reflective element;
an attachment portion;
wherein said attachment portion is configured for attaching at a side of a vehicle;
wherein said mirror reflective element comprises a front substrate and a rear substrate and an electrochromic medium disposed between said front and rear substrates;
wherein said front substrate has a first surface and a second surface and wherein a transparent electrically conductive layer is disposed at said second surface of said front substrate;
wherein said rear substrate has a third surface and a fourth surface and wherein a mirror reflector is disposed at at least a portion of a surface of said rear substrate;
wherein said mirror reflector comprises a stack of thin films and wherein said stack of thin films comprises at least a first thin film and a second thin film;
wherein said first thin film is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm;
wherein said second thin film is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm;
wherein said electrochromic medium is disposed in an interpane cavity between said third surface of said rear substrate and said second surface of said front substrate and is bounded by a perimeter seal;
wherein no part of said rear substrate extends beyond any part of said front substrate;
wherein a perimeter layer is disposed at said second surface of said front substrate proximate a perimeter edge of said front substrate, and wherein said perimeter layer comprises a reflective perimeter layer;
wherein said perimeter layer comprises at least one thin metal film and wherein said perimeter layer is electrically conductive;
wherein said perimeter layer generally conceals said perimeter seal from view by a driver of the vehicle normally viewing said front substrate when said exterior rearview mirror assembly is mounted at the vehicle;
wherein said exterior rearview mirror assembly comprises a light source;
wherein said light source comprises a light source of an indicator;
wherein said light source comprises a plurality of light emitting diodes, and wherein at least some of said light emitting diodes each individually passes less than about 75 milliamps forward current when powered;
and
wherein light emitted by said light source, when powered, is substantially not visible to the driver of the vehicle when the driver is normally operating the vehicle.

17 more elements

An exterior rearview mirror assembly suitable for use for a vehicle, said exterior rearview mirror assembly comprising:

a casing portion;
wherein said casing portion comprises a variable reflectance mirror reflective element;
an attachment portion;
wherein said attachment portion is configured for attaching at a side of a vehicle;
wherein said exterior rearview mirror assembly comprises a driver-side exterior rearview mirror assembly;
wherein said mirror reflective element comprises a front substrate and a rear substrate and an electrochromic medium disposed between said front and rear substrates;
wherein said front substrate has a first surface and a second surface and wherein a transparent electrically conductive layer is disposed at said second surface of said front substrate;
wherein said rear substrate has a third surface and a fourth surface and wherein a mirror reflector is disposed at at least a portion of said third surface of said rear substrate;
wherein said mirror reflector comprises a stack of thin films and wherein said stack of thin films comprises at least a first thin film and a second thin film;
wherein said first thin film is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm;
wherein said second thin film is formed of a material that has a specific resistivity of less than about 1×10−2 ohm·cm;
wherein said electrochromic medium is disposed in an interpane cavity between said third surface of said rear substrate and said second surface of said front substrate and is bounded by a perimeter seal;
wherein no part of said rear substrate extends beyond any part of said front substrate;
wherein a perimeter layer is disposed at said second surface of said front substrate proximate a perimeter edge of said front substrate, and wherein said perimeter layer comprises a reflective perimeter layer;
wherein said perimeter layer comprises at least one thin metal film and wherein said perimeter layer is electrically conductive;
wherein said perimeter layer generally conceals said perimeter seal from view by a driver of the vehicle normally viewing said front substrate when said exterior rearview mirror assembly is mounted at the vehicle;
wherein said mirror reflective element comprises a curved mirror reflective element having a more curved outboard region and a less curved inboard region;
a demarcation that demarcates said more curved outboard region of said mirror reflective element from said less curved inboard region of said mirror reflective element;
wherein at least one of (i) said front substrate has a thickness of about 0.063 inches or less, (ii) said rear substrate has a thickness of about 0.063 inches or less, (iii) said front substrate has a thickness of about 0.063 inches or less and said rear substrate has a thickness of about 0.063 inches or less, (iv) at least one of said front substrate and said rear substrate has a thickness of about 0.043 inches or less, and (v) one of said front substrate and said rear substrate has a thickness of about 0.063 inches or less and the other of said front substrate and said rear substrate has a thickness of about 0.043 inches or less;
wherein said exterior rearview mirror assembly comprises a light source;
wherein said light source comprises a plurality of light emitting diodes, and wherein at least some of said light emitting diodes each individually passes less than about 75 milliamps forward current when powered;
and
wherein light emitted by said light source, when powered, is substantially not visible to the driver of the vehicle when the driver is normally operating the vehicle.

20 more elements

An exterior rearview mirror assembly suitable for use for a vehicle, said exterior rearview mirror assembly comprising:

a casing portion;
wherein said casing portion comprises a variable reflectance mirror reflective element;
an attachment portion;
wherein said attachment portion is configured for attaching at a side of a vehicle;
wherein said mirror reflective element comprises a front substrate and a rear substrate and an electrochromic medium disposed between said front and rear substrates;
wherein said front substrate has a first surface and a second surface and wherein a transparent electrically conductive layer is disposed at said second surface of said front substrate;
wherein said rear substrate has a third surface and a fourth surface and wherein a mirror reflector is disposed at at least a portion of said third surface of said rear substrate;
wherein said mirror reflector comprises a stack of thin films and wherein said stack of thin films comprises at least a first thin metal film and a second thin metal film;
wherein said first thin metal film is formed of a metal that has a specific resistivity of less than about 1×10−3 ohm·cm;
wherein said second thin metal film is formed of a metal that has a specific resistivity of less than about 1×10−3 ohm·cm;
wherein said electrochromic medium is disposed in an interpane cavity between said third surface of said rear substrate and said second surface of said front substrate and is bounded by a perimeter seal;
wherein no part of said rear substrate extends beyond any part of said front substrate;
wherein a perimeter layer is disposed at said second surface of said front substrate proximate a perimeter edge of said front substrate, and wherein said perimeter layer comprises a reflective perimeter layer;
wherein said perimeter layer comprises at least one thin metal film and wherein said perimeter layer is electrically conductive;
wherein said perimeter layer generally conceals said perimeter seal from view by a driver of the vehicle normally viewing said front substrate when said exterior rearview mirror assembly is mounted at the vehicle;
wherein said exterior rearview mirror assembly comprises a light source;
wherein light that reflects off of said mirror reflector and passes through said electrochromic medium and said front substrate has a substantially untinted reflectant characteristic to a person normally viewing said front substrate of said mirror reflective element when no voltage is applied to said electrochromic medium;
wherein said light source comprises a plurality of light emitting diodes and wherein at least some of said light emitting diodes each individually passes less than about 75 milliamps forward current when powered;
and
wherein light emitted by said light source, when powered is substantially not visible to the driver of the vehicle when the driver is normally operating the vehicle.

17 more elements

Dependencies are inferred from the claim text.

Facts

Application: 13/716,766Filed 17 Dec 2012 · continuation
Priority: 20 Sep 2002
Published: US 2013/0107563 A12 May 2013
Granted: 5 Aug 2014
Term ends: Not estimatedThe source records don’t support an estimate.

Classification22 codes

B60R 1/088
Anti-glare mirrors, e.g. "day-night" mirrors: using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or…
B60Q 1/2665
Mounted on parts having other functions: on rear-view mirrors
B60Q 1/34
The devices being primarily intended to indicate the vehicle, or parts thereof, or to give signals, to other traffic: for indicating change of…
B60R 1/04
Rear-view mirror arrangements: mounted inside vehicle

Family

Application60/412,275Us provisional application · filed 20 Sep 2002
Application60/423,903Us provisional application · filed 5 Nov 2002
Application60/424,116Us provisional application · filed 5 Nov 2002
Application60/489,816Us provisional application · filed 24 Jul 2003
Application60/490,111Us provisional application · filed 25 Jul 2003
PCT/US03/29776Parent of this continuation-in-part · filed 19 Sep 2003
PCT/US03/35381Parent of this continuation · filed 5 Nov 2003
Application11/709,625Parent of this continuation · filed 22 Feb 2007
US 7,184,190 B2Parent of this continuation · filed 27 Feb 2007
US 7,274,501 B2Parent of this continuation-in-part · filed 25 Sep 2007
Application11/956,893Parent of this continuation · filed 14 Dec 2007
US 7,310,177 B2Parent of this continuation · filed 18 Dec 2007
Application12/429,620Parent of this continuation · filed 24 Apr 2009
US 7,525,715 B2Parent of this continuation · filed 28 Apr 2009
Application12/727,691Parent of this continuation · filed 19 Mar 2010
US 7,710,631 B2Parent of this continuation · filed 4 May 2010
Application12/979,492Parent of this continuation · filed 28 Dec 2010
US 7,864,399 B2Parent of this continuation · filed 4 Jan 2011
US 2013/0107563 A1Pre-grant publication · published 2 May 2013
US 8,335,032 B2Parent of this continuation
Application10/533,762Parent of this continuation
Application10/528,269Parent of this continuation-in-part
Application10/533,762Parent of this continuation-in-part
US 2006/0050356 A1Published application
US 2006/0098289 A1Published application
US 2007/0153356 A1Published application
US 2008/0180779 A1Published application
US 2009/0207514 A1Published application
US 2010/0172008 A1Published application
US 2011/0096387 A1Published application
US 8,797,627 B2This patent

From the US filing history. Foreign family members aren’t listed.